Object Launching System for Well

ABSTRACT

An object launching apparatus for a well has a housing, a flow mandrel, and a cage. The flow mandrel is disposed in the housing&#39;s internal chamber, and a flow passage in the mandrel communicates flow from the housing&#39;s inlet to the mandrel&#39;s flow port, which in turn communicates with the housing&#39;s outlet. The cage is disposed in the internal chamber and defines pockets for holding the objects. A motor and shaft move the cage in the housing relative to the mandrel&#39;s flow port so the cage&#39;s pockets can be selectively positioned in communication between the mandrel&#39;s flow port and the housing&#39;s outlet. This allows any of the object(s) held in the positioned pocket to be launched into the flow to the well. Preferably, the motor rotates the shaft so the cage can ride linearly along the shaft&#39;s thread and the cage can rotate through a cammed engagement with the housing.

BACKGROUND OF THE DISCLOSURE

Various launching apparatus are used with wellheads to deploy balls, plugs, darts, chemical sticks, or other devices downhole. The devices can be used for various purposes, such as actuating downhole tools, closing off fluid flow, blocking slots in liners, treating zones of a formation, etc.

Some launching apparatus use auger mechanisms to deploy balls, such as disclosed in U.S. Pat. No. 4,889,259. Other launching apparatus use carousel or cartridge mechanisms, such as disclosed in U.S. Pat. No. 8,091,628. Still others use hoppers, such as U.S. Pat. No. 7,987,928, or have gumball-type mechanisms, such as U.S. Pat. No. 7,552,763. Some launching apparatus use clips, such as disclosed in US Pub. 2012/0211219, or use a movable magazine, such as disclosed in US Pub. 2008/0223587.

Launching apparatus are also disposed inline or on top of wellheads. For example, U.S. Pat. No. 8,256,514 discloses an apparatus that positions on top of a wellhead and uses individual retainers to hold individual balls in a long bore of the apparatus. As shown in FIGS. 1A-1B, for example, the apparatus in U.S. Pat. No. 8,256,514 has a body 10 with the long bore 16 running therethrough. The long bore 16 allows downhole actuation devices 26 (e.g., balls) and possibly fluid to travel from the top end 14 of the body 10 to the bottom end 12.

The top end 14 can have a cap 19 to provide access to the long bore 16, and the bottom end 12 connects to a pumping block 30 disposed on a wellhead 15. A fluid delivery line 34 connects to the pumping block 30 to continuously introduce fluid into the wellhead 15.

On the apparatus, a series of side ports 18 are spaced along the sides of the body 10 of the apparatus. Retainers 20 are inserted through each port 18 to hold the balls 26 in spaces 22 within the long bore 16. The retainers 20 are moveable within the ports 18 to extended and retracted positions relative to the long bore 16 to control the passage of the balls 26 through the bore 16.

To load the balls 26, a lower retainer 20 is positioned in a blocking position while all other retainers 20 between it and the top end 14 are retracted. A ball 26 is loaded through the opened top end 14 to the long bore 16 to drop into position onto the extended retainer 20. This is repeated up the apparatus to load the other balls 26 in the long bore 16 on the various retainers 20.

Once all desired balls 26 are loaded into the apparatus and are resting in the spaces 22 upon the individual retainers 20, the top end 14 may be sealed. To launch the balls 26, the first ball 26 closest to the wellhead 15 is released first, followed by the next closest ball 26. This can be repeated up the apparatus 10 to launch successive balls 26 into the well.

Releasing a retainer 20 causes the ball 26 resting upon the retainer 20 to fall into the wellhead 15 and into the fluid being introduced into the wellhead 15 through the pumping block 30 via the line 34. Once the ball 26 has been launched into the wellbore and completed its desired operation therein, an operator may use a control panel to drive a cylinder into a released position so that the next retainer 20 is moved to release another ball 26 into the wellbore. This process may continue releasing the balls 26 into the wellbore sequentially moving up the bore 16.

The balls 26 may be launched by gravity. If desired, a fluid conduit 38 may be connected from the flow line 34 to the top end 14 to provide fluid flow down through bore 16 to act as a pushing force for launching the balls 26. The conduit 38 has a valve 36, which can be closed when a ball 26 is not being launched. When launching a ball 26, the valve 36 may then be opened to permit the flow of fluid through the fluid conduit 38 and into the bore 16 from the top end 14. The valve 36 may be manually or remotely operated by hydraulic, pneumatic, or robotic controls. In the end, the flow of fluids through line 34 into long bore 16 from top end 14 may provide force, in addition to gravity, to assist in pushing the balls 26 through the long bore 16 into the wellhead 15.

Some launching apparatus use side pockets from which balls can be deployed into a central housing and then into the wellbore. For example, FIG. 1C illustrates a cross-sectional view of another launching apparatus as disclosed in U.S. Pat. No. 7,571,773. A multiple ball launch assembly 30 has ball launch pods 40 disposed an outer wall of a housing 32. A flow tube 34 disposed in the housing 32 rotates to align a first opening 35 in the flow tube 34 with a first ball launch pod 40 so a first ball B can be launched from the pod 40 and into the housing 32. As the flow tube 34 is further rotated, subsequent openings 35 in the flow tube 34 align with the other ball launch pods 40 so that the balls B held in those pods 40 can enter the housing 32 and pass to the wellbore. A drive 36 on the housing 32 rotates the flow tube 34, and a flush line inlet 38 on the housing 32 allows fluid to be pumped into or out of the assembly 30.

Although many launching apparatus in the art may be useful, they may be cumbersome to install at a wellsite and may be complicated to assemble and operate. Additionally, the launching apparatus used in the art may not readily allow for remedial actions if operations fail (e.g., if a ball is not launched, if a ball is improperly loaded, if the ball fails to reach its operational goal, etc.).

The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.

SUMMARY OF THE DISCLOSURE

An object launching apparatus for a well has a housing, a flow mandrel, and a cage. The flow mandrel is disposed in the housing's internal chamber, and a flow passage in the mandrel communicates flow from the housing's inlet to the mandrel's flow port, which in turn communicates with the housing's outlet. The cage is disposed in the internal chamber and defines pockets around an axis of the cage for holding the objects. In particular, the cage can define an internal passage in which the flow mandrel is disposed so as the cage moves in the housing's internal chamber and moves around its axis on the flow mandrel.

A motor and shaft move the cage in the housing relative to the mandrel's flow port. For example, a bearing can couple the shaft to the cage, and the bearing can move along threads of the rotated shaft. As the cage is moved, the cage's pockets can be selectively positioned in communication between the mandrel's flow port and the housing's outlet. This allows any of the object(s) held in the positioned pocket to be launched into the flow to the well.

A controller is operably coupled to the motor and controls movement of the cage in the housing. The cage is movable at least in a linear direction in the housing relative to the flow port of the flow passage. Preferably, the motor rotates the shaft so the cage can ride linearly along the shaft's thread and the cage can rotate through a cammed engagement with the housing. The cammed engagement translates linear movement of the cage in the housing's internal chamber to radial movement of the cage in the internal chamber. For example, the cage can have one or more guides disposed thereon, and an internal surface of the chamber can define a channel in which the one or more guides can ride.

A sensor detects the position of the cage in the housing. The sensor can be disposed in the housing and can detect one or more sensing elements disposed on the cage. Additionally, a lock can be used to lock the cage in position in the housing between movements. The lock can be movable in the housing relative to the cage and can selectively engage with the cage to hold it in place. For example, the lock can include a pin selectively engageable in the pockets of the cage.

An inlet connection coupled to the housing's inlet receives flow for communication with the mandrel's flow passage of the flow mandrel. This inlet connection can have a valve operable to control communication of the flow. An outlet connection coupled to the housing's outlet supplies the flow to the well. This outlet connection can also have a valve operable to control communication of the flow.

The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate an elevational view and a cross-sectional view of a launching apparatus according to the prior art.

FIG. 1C illustrates a cross-sectional view of another launching apparatus according to the prior art.

FIG. 2 schematically illustrates an object launching system according to the present disclosure for a fracture treatment system of a well.

FIG. 3A illustrates a perspective view of a launch device for the disclosed system.

FIGS. 3B-3C illustrate perspective views of the launch device in cross-section along two orthogonal planes.

FIG. 4 illustrates a perspective view of the housing of the disclosed launch device along a cross-sectional plane.

FIG. 5 illustrates a perspective view of the flow mandrel for the disclosed device along a cross-sectional plane.

FIG. 6A illustrates an elevational view of the cage of the disclosed launch device.

FIGS. 6B-6C illustrate perspective views of the cage in cross-section along two orthogonal planes.

FIG. 7 illustrates a perspective view of the drive shaft and the cage of the disclosed launch device.

FIGS. 8A-8B illustrate cross-sectional views of the launch device along two orthogonal planes.

FIGS. 8C, 8D-1, and 8D-2 illustrate cross-sectional views of an alternative configuration of the launch device along two orthogonal planes.

FIGS. 9A-9C illustrate cross-sectional views of the launch device during stages of operation.

FIG. 10A schematically illustrates a control unit and other components of the object launching system.

FIG. 10B shows an example operational sequence performed by the disclosed system in launching objects.

FIGS. 11A-11C illustrate cross-sectional views of another launch device during stages of operation.

FIGS. 12A-12B illustrate end-sectional and cross-sectional views of yet another launch device.

FIGS. 13-14 illustrate alternative configurations of the disclose launch device used with a fluid system of a well.

DETAILED DESCRIPTION OF THE DISCLOSURE

As schematically illustrated in FIG. 2, an object launching system 100 according to the present disclosure can be used with a fluid system 50 of a well. The fluid system 50 is only representatively illustrated having a pump 52 and tubing 54 for directing fluid flow to a wellhead 56. Any of the other components of such a fluid system 50 are known in the art and are not represented here.

The launching system 100 launches objects into the well and can operate in conjunction with the fluid system 50. For its part, the fluid system 50 can be any suitable fluid system for use with a well in which objects are deployed. For example, the fluid system 50 can be a fluid treatment system used to treat zones of a formation, such as a fracture treatment system for fracturing zones of the formation. In general, the objects to be launched can be balls, plugs, darts, chemical pills or sticks, RFID tags, or other devices used for various purposes, such as actuating downhole tools, closing off fluid flow, blocking slots in liners, treating zones of a formation, etc.

Although it can be used in conjunction with the fluid system 50, the launching system 100 can be disposed apart from the wellhead 56. For example, the components of the launching system 100 can be disposed on a skid, a trailer, or the like (not shown) and does not need to be mounted on or atop the wellhead 56. An inlet conduit 102 connects to the fluid system's tubing 54 and can have an inlet valve 104. In a similar manner, an outlet conduit 106 connects to the fluid system's tubing 54 and can have an outlet valve 108. In other configurations, however, the launching system 100 can be mounted on the wellhead 56 and/or may not use an inlet conduit 106.

As will be discussed in more detail below, the launching system 100 includes a control unit 110, a motor 120, and a launch device 150. The control unit 100 can be any suitable type of control unit for use at a wellsite and can include one or more of a computer, a microcontroller, memory, processor, input/output interface, etc.

The motor 120 can be an electric motor, a hydraulic motor, a pneumatic motor, or any other suitable actuation device to impart rotation and/or axial motion. The motor 120 may also be controllable to operate to known and designated positions. The motor 120 is controlled by the control unit 110 to launch objects (e.g., plugs, balls, RFID tags, or any suitable object) in the launch device 150 down the well according to the purposes disclosed herein.

The launch device 150 holds a plurality of objects (e.g., plugs, balls, tags, chemical slugs, etc.) therein to be deployed down the wellhead 56 to operate various downhole sliding sleeves, packers, etc.; to treat parts of the wellbore, or to achieve any other appropriate purposes related to the well. An inlet 152 of the launch device 150 connects to a fluid source (i.e., to the inlet conduit 106 to receive at least some of the fluid flow from the system's tubing 54). An outlet 156 of the launch device 150 connects to the outlet conduit 106 for delivery of the launched objects (and any diverted fluid flow) into the flow stream passing through the system's tubing 54 from the pump 52 to the wellhead 56. Thus, the fluid flow from the fluid system 50 may be intended to pass through the launch device 150 to launch the objects into the well.

Although the launch device 150 is shown connected as in FIG. 2 along bypass tubing 102 and 106 to the supply tubing 54 from the pump 52 to the wellhead 56, other configurations can be used. In other embodiments, it is possible that an inlet 152 is not provided or is not connect to the fluid flow so that deployment of the objects from the launch device 150 to the wellhead 56 may rely on gravity, suction, and the like. For example, the launch device 150 may not receive diverted fluid flow through inlet tubing 102 and may instead connect only to the supply tubing 54 with the outlet conduit 106. In this case, flow of fluid through the supply tubing 54 can draw objects from the launch device 150 using gravity, suction, venturi effect, and the like. Alternatively, the inlet 152 of the launch device 150 may connect to an auxiliary fluid supply, such as water, drilling fluid, etc., that is separate from the supply tubing 54 from the pump 52.

Additional ports 154, 155, and 158 may be provided on the launch device 150 for other purposes disclosed herein. For example, a lockout unit 130 can couple to one such port 155 or 158 for locking internal components of the launch device 150 during operations. Further details related to such a lockout unit 130 are discussed below with reference to FIGS. 8D-2.

General operation of the object launching system 100 involves opening the valves 104 and 108 for communication with the fluid flow of the fluid system's tubing 54. When a first of a number of objects is to be launched and deployed downhole for some purpose, the control unit 110 either automatically (or in conjunction with a user input) activates the motor 120. In turn, the motor 120 moves a drive shaft 190 coupled to internal components of the launch device 150 so that the first object(s) align in the diverted flow passing from the inlet 152 to the outlet 156 of the launch device 150. As a result, the first object(s) leave the launch device 150 and flow into the flow of the tubing 54 to the wellhead 56.

The control unit 110 can monitor the position of internal components of the launch device 150 using one or more position sensors 115 and can monitor the deployment of the launched object(s) in the fluid flow using one or more other detection sensors 116. The control unit 110 can also activate the lockout unit 130 to prevent additional movement of internal components in the launch device 150. Additional details related to the control unit 110 and its operational scheme are discussed below with reference to FIGS. 10A-10B.

At some point during operations, a second of the objects is deployed downhole to achieve some purpose. For example, the second object may be a plug or ball used to open another sliding sleeve downhole so a fracture treatment can be applied to a different zone of the formation. The system 100 operates in a similar fashion activating the motor 120 to align the second object(s) in the flow from the inlet 152 to the outlet 156 of the launch device 150 and to launch the second object(s) in the flow stream to the wellhead 56.

It may be necessary at some point to reload objects, replace loaded objects, load new objects, or somehow alter what is preconfigured in the launch device 150. The other ports 154 and 158 can be used for these purposes as will be discussed later. Moreover, the motor 120 and control unit 110 can be operated to reset the launch device 150 as needed.

Having a general understanding of the object launching system 100, further details related to the launch device 150 are now discussed in conjunction with a number of Figures. In particular, FIG. 3A illustrates a perspective view of the launch device 150, and FIGS. 3B and 3C illustrate perspective views of the launch device 150 in cross-section along two orthogonal planes.

As shown in FIGS. 3A through 3C, the launch device 150 includes a housing or body 160, a flow mandrel 170, a cage 180, and a drive shaft 190. The housing 160 defines an internal bore or passage 162 in which the flow mandrel 170, the cage 180, and the drive shaft 190 position. (For further reference, FIG. 4 illustrates a perspective view of the housing 160 in isolated cross-section without the internal components.) An inlet flange 152 affixes to one end 161 a of the housing 160 to enclose an inlet side of the housing 160, and a drive side flange 153 affixes to the opposing end 161 b of the housing 160 to close off the housing's bore 162.

The various ports 154, 155, 156, and 158 disposed around the housing 160 are provided with flanges for coupling to tubing, caps, or other components. The inlet 152 is intended to conduct fluid into the launch device 150, and the outlet 156 is intended to conduct flow exiting the launch device 150 when communicated from the inlet flange 152. Therefore, the outlet 156 can communicate with a conduit (106: FIG. 2) to deliver objects to the flow of the main tubing (54: FIG. 2).

The secondary port 154 is used for reloading or unloading objects as desired so this port 154 may have a removable cap or other pressure isolation feature (not shown) that can be selectively opened or removed to introduce objects therethrough. One of the other ports 155 and 158 can be used for holding the lockout unit (130: FIG. 2) discussed previously, and the two ports 155 and 158 can be used for filling and unfilling the device 150 with objects before, during, and after certain operations.

The flow mandrel 170 has a flanged end 174 that affixes to the inlet flange 152 so that an internal flow passage 172 of the mandrel 170 can communicate the inlet flange 152 with an outlet 176 on the flow mandrel 170. (For further reference, FIG. 5 shows a perspective view of the flow mandrel 170 in isolated cross-section.)

When disposed in the housing 160, the flow port 176 is arranged to communicate and align with the outlet port 156 on the housing 160. In this way, fluid flow from the inlet flange 152 can flow through the internal passage 172 of the mandrel 170, exit the mandrel's outlet 176, and pass out of the launch device 150 through the outlet port 156. For sealing purposes, saddle seals (not shown) or other sealing mechanism can be used on the mandrel 170 around the flow port 176 and can be used on the inside of the housing's chamber 162 at the outlet 154 (as well as the other ports 155, 156, and 158).

The cage 180 is disposed inside the housing's bore 162 and is disposed on the flow mandrel 170. (For further reference, FIGS. 6A through 6C illustrate a side view and isolated perspective views of the cage 180 along two orthogonal cross-sections, and FIG. 7 illustrates a perspective view of the exterior of the cage 180 with the drive shaft 190 coupled at one end.) In particular, the cage 180 has a through-pocket 182 that fits on the mandrel 170 so that the cage 180 can move (e.g., rotate and slide) on the flow mandrel 170 within the housing's bore 162. A plurality of pockets 184 defined in the side of the cage 180 can be selectively aligned between the mandrel's outlet 176 and the housing's outlet port 156 depending on the axial and radial orientation of the cage 180 in the housing 160. In this way, any objects held within a given pocket 184 can be introduced into the flow through the launch device 150 depending on how the cage 180 is positioned in the housing 160 relative to the flow mandrel's outlet 176 and the device's outlet 156.

Finally as shown in FIGS. 3A through 3C, the drive shaft 190 passes through a bonnet 192 and packing glands 194 in the drive side flange 153 and connects at its distal end to the end of the cage 180. Thrust and dynamic bushings 189 connect the drive shaft 190 to the flow mandrel 170. The proximal end of the shaft 190 couples to the motor (120) to impart movement to the shaft 190 and, in turn, to move the cage 180. As presently illustrated, the distal end of the draft shaft 190 rests on the end of the flow mandrel 170, and the drive shaft 190 rotates by operation of the motor (120) to draw the cage 180 axially within the bore 162 of the housing 160. Other arrangements can be used as disclosed below or as appreciated by one skilled in the art with the benefit of the present disclosure.

Turning now to FIGS. 8A and 8B, which illustrate cross-sectional views of the launch device along two orthogonal planes, the various pockets 184 of the cage 180 are loaded with objects. Depending on the sizes of the objects, one or more than one object may be held in a given pocket 184 depending on the implementation and the desired operation. As noted previously, loading the objects in the pockets 184 can involve moving the cage 180 in the housing 160 and inserting the objects into the pockets 184 through one or more of the ports 154, 155, 156, and 158.

Turning to FIG. 8C, another cross-sectional view of the launch device 150 is depicted. The device 150 as shown here may not include integrated flanges associated with the ports 154 and 156 (as well as those not shown). Instead, the housing 160 of the device 150 can be flush at the ports 154 and 156 and may define slots for gaskets and bolt holes (not shown).

As shown in the cross-sectional view of FIG. 8D-1 offset by 90-degrees, the ports (namely port 155 and 158) on the device 150 can include sealed closure bonnets 140 for closing off the ports 155 and 158 when not in use. The bonnet 140 can include a flange body 141 that affixes to the housing 160 at the port 155 and 158 using studs or the like. An end cap 146 has a stem 142 extending therefrom, which is disposed through the flange body 141 and has an end plate 144 for covering the inside of the port 155 and 158 at the housing 160. A hold-down ring 147 affixes to the flange body 141 to hold the end cap 146 and stem 142 in place. A bleed port 148 may be provided in the end cap 146 for various purposes. The stem 142 and the end plate 144 preferably have holes, slots, or the like to prevent trapping fluid pressure.

As shown in the cross-sectional view of FIG. 8D-2, one of the ports (e.g., 158) may have a lockout unit 130 for locking the cage 180 in place during operation for the purposes disclosed herein. The lockout unit 130 shown here includes a piston 132 movable into and out of the port 158 and any aligned pocket 184 of the cage 180. A spring 134 may bias the piston 132 to an engaged or locked position extending through the port 158 and into the aligned pocket 184, which would represent the last pocket 184 from which an object has been deployed. A hydraulic chamber 136 can fill with fluid pressure to move the piston 132 to a disengaged condition, which would allow the cage 180 to be moved. As will be appreciated, this lockout unit 130 represents one of several possible devices for engaging and disengaging the cage 180 to respectively prevent and allow movement of the cage 180.

Given the above-description of some of the components of the object launching system 100 and the launch device 150, discussion now turns to an overview of the operation of the system 100 with reference to FIGS. 9A-9C.

For the purposes of discussion, the objects in the present example are balls B used in well operations, such as used to open sliding sleeves and close seats for fracture treatments to various zones of a formation. As already noted, any suitable type of object can be deployed with the launch device 150. In any event, the balls B are typically loaded around the pockets 184 in a desired order for being deployed. Thus, pockets 184 at one end of the cage 180 may hold smaller balls B to be deployed downhole first to reach smaller seats or restrictions down the tubing string in the well. The balls B in successive pockets 184 along the cage 180 can then increase in size to engage progressively larger seats or restrictions. Of course, any desired arrangement can be used.

As specifically shown, each of the pockets 184 can be generally the same size as one another to accommodate a range of object sizes, but this is not strictly necessary. It is possible that the cage 180 can have individual pockets 184 arranged with particular sizes to accommodate particular sized objects. Moreover, the pockets 184 could have spacers or rings affixed therein to reduce their diameter to a given size to accommodate different sizes.

With the balls B loaded, the launch device 150 can be used to deploy the loaded balls B either manually or automatically into well. If not already coupled to the fluid system (50), for example, the launch device 150 and other components of the launching system (100) can be arranged to accept at least some flow of the fluid from the pump (52) therethrough so that the balls B held in the cage 180 can be selectively deployed into the fluid stream to be introduced downhole of the wellhead (56).

The system (100) can be configured for the flow to automatically pass into the launch device 150, the system (100) may require operators to manually open the inlet valve 104 and/or outlet valve 108, or the system (100) may have automated valve actuators to open in the valves 104 and/or 108. Regardless of how the flow is controlled, the control unit 110 can detect the flow with a flow sensor 242 and can use that information in the control of the system 100.

When a first ball in one of the pockets 184 (namely, the topmost pocket 184) is to be deployed, the cage 180 is moved by the motor (120) and the drive shaft (190) to a first position, such as shown in FIG. 9A. The topmost pocket 184 aligns between the mandrel's outlet 176 and the housing's outlet 156. Fluid can then be introduced through the flow mandrel 170 from the inlet 152 of the housing 160 to flow through the mandrel's bore 172 and force the ball B out of the pocket 184 and the outlet port 156, from which the ball B can be introduced into the fluid stream to the wellhead (56).

After the first ball B is launched, another ball B will be deployed at some point depending on the implementation. The motor (120) moves the cage 180 inside the housing's bore 162. In the current embodiment, portion of the housing's bore 162 defines a channel 165, a cam surface, a thread, or the like. On the exterior of the cage 180 as shown in FIGS. 9A (as well as in FIG. 7), the cage 180 can have one or more guides 185, rollers, pins, bearings, or the like. The guides 185 can ride in the housing's channel 165. With this arrangement, rotation of the drive shaft 190 by the motor (120) moves the cage 180 linearly or axially within the housing's bore 162, as the bearing 189 rides on the thread of the shaft 190. With the linear movement of the cage 180, the cammed engagement between the cage's guides 185 and the housing's channel 165 causes the cage 180 to rotate within the bore 162 as it moves axially therealong. This selectively aligns the various pockets 184 in the cage 180 between the mandrel's outlet 176 and the housing's outlet port 156.

The cammed engagement can have a reverse arrangement where the channel, cam surface, or the like may be defined on the outside of the cage 180 and the one or more guides, rollers, pins, bearings, or the like can be disposed inside the bore 162. Alternatively, both the inside of the housing's bore 162 and the outside surface of the cage 180 can have mating threads or channeled surfaces to impart rotation of the cage 180 as it is moved axially in the housing 160. These and other cammed engagements can be used.

Other than the cammed engagement, the cage 180 can be rotated and moved axially in a number of other ways as well. In the current embodiment, the drive shaft 190 is a non-rising stem that is rotated and does not move axially. Thus, the motor (120) rotates the drive shaft 190 so that the cage 180 is pulled along the drive shaft 190 by the bearing 189 on the cage 180 riding along the shaft's threaded surface. In other embodiments, the drive shaft 190 may be attached to the cage 180 with a rotatable coupling, and the drive shaft 190 can be moved axially along the housing 160 to pull the cage 180, which is allowed to rotate on the drive shaft 190 with the cammed engagement. In still other embodiments, the drive shaft 190 can be a rising stem that is fixedly coupled to the cage 180, and the motor (120) may both rotate and axially move the cage 180 in the housing 160 without a particular cammed engagement between the cage 180 and the housing 160.

Eventually, as shown in FIG. 9B, the launch device 150 can reach an intermediate stage of operation, where additional balls B have been launched from the pockets 184, and a more intermediate pocket 184 has aligned between the mandrel's outlet 176 and the housing's outlet port 156. Finally, as shown in FIG. 9C, the launch device 150 can reach a final stage of operation, where a final ball B has been launched from the last pocket 184 aligned between the mandrel's outlet 176 and the housing's outlet port 156.

At any point during operation, a ball B can be filled into a previously used pocket 184 using one of the alternate outputs 154, 155, or 158. For example, the cage 180 can be retracted so that a particular pocket 184 can align with the port 154 for inserting a new ball B in the previously emptied pocket 184. This may be useful if a previously deployed ball B from a pocket 184 failed to achieve its intended purpose downhole because it became lost, was defective, broke apart, etc. Refilling through the port 154 may require isolating the launch device 150 from fluid flow by closing the connecting valves (104 and 106) and removing a closure bonnet (e.g., 140: FIG. 8D-1) from the port 154.

To determine the position of the cage 180 within the housing 160, the launching system 100 as shown in FIG. 2 can use one or more proximity sensors 115 disposed on the launch device 150. As shown in FIG. 4, for example, the housing 160 can define a slot 163 communicating with the housing's bore 162 where the cage 180 disposes. The slot 163 can hold a position sensor (115), such as a Hall Effect sensor, an RFID reader, optical sensor, or the like. This sensor (115) can detect passage of magnetic elements, RFID tags, optical elements, or other sensing elements disposed at particular locations along the outside surface of the cage 180. As shown in FIG. 6A, for example, various points 187 on the cage 180 may accommodate sensing elements, such as magnets, RFID tags, or the like. These points 187 may be located proximate to the pockets 184 so that when a given point 187 aligns with the sensor (115) in the sensor slot 163 on the housing 160, the pocket 184 associated with that point 187 is aligned with the housing's outlet port 156. Thus, as the cage 180 is moved in the housing 160, for example, the sensor (115) in the slots 163 can detect the passage of the sensor elements at the points 187 on the cage 180 to determine the position of the cage 180. In turn, this can correlate to an indication of which of the pockets 184 on the cage 180 are aligned with the mandrel's outlet 176 and the housing's outlet 156.

The control unit 110 may simply count the detected passage of the sensing elements at the points 187 with the sensor (115). Alternatively, the sensing elements at the points 187 can be specifically identifiable, such as RFID tags, disposed on the cage 180. In this way, detection by the sensor 115 of a particular tag can identify the orientation of the cage 180 in the housing 160.

As disclosed above, the housing's inlet 152 receives flow, which passes through the flow mandrel 170 to the housing's outlet 156. It is entirely possible that the inlets and outlets can be reversed, which would still allow the device 150 to operate in the same way, albeit under a reverse flow regime. Therefore, the port 152 (previously termed “inlet”) can be the housing's outlet, and port 156 (previously termed “outlet”) can be the housing's inlet. Flow then through the flow mandrel 170 would pass from flow port 176 to the opening at the flanged end 174 along the flow passage 172.

Finally, the launch device 150 may not include a flow mandrel 170. Instead, the cage 180 can be moved in the housing 160 along the axis of the cage 180 as before without riding on a flow mandrel 170. Each of the pockets 184 can be freely open on the outside surface of the cage 180 for passage of the objects from the pockets 184. The cage 180 may also include its through-pocket 182 through which fluid can flow to at least one of the pockets 184 aligned with the outlet 156. The insides surfaces of the object pockets 184 may be partially closed, may have flow slots, or the like or the through-pocket 182 can be lined with a slotted sleeve or filter to keep the objects in the pockets 184 but allow fluid flow from the through-pocket 182 into the object pockets 184 to launch the objects. During operations, fluid flow entering the inlet 152 can pass into the through-pocket 182 of the cage 180. Although the flow can communicate with the various object pockets 184, only the object disposed in the pocket 184 aligned with the housing's outlet 156 would allow fluid flow therethrough to launch the object contained therein.

FIG. 10A schematically shows the control unit 110 and other components of the object launching system 100. The control unit 110 is configured for manual operation 112 and for automated operation 114. To achieve the automated operation 114, the control unit 110 may be set with one or more programs 118 to control operation of the object launching system 100 and may use timers 119 to initiate various automated actions.

The control unit 110 has various control functions to implement operations with other components of the system 100. A motor controller 220 obtains sensed information from the position sensors 115 of the launch device 150 indicating the location of the cage 180 in the housing 160 and by extension indicating which pocket 184 is aligned with the outlet port 156. The motor controller 220 also controls operation of the motor 120 used to move the cage 180 in the housing 160.

A flow controller 240 of the control unit 110 can obtain sensed information from flow sensors 242 disposed at various locations in the system 100, such as at the inlet 152 and outlet port 156 and/or connecting tubing (104 and 106). The flow controller 240 can also operate various valve actuators to control the flow of fluid through the system 100. Therefore, the control unit 110 can detect if flow is present or not and can actuate the various valves 104 and 108 of the system 100 accordingly.

A lock controller 230 can control operation of the lockout unit 130 of the system 100. The lockout unit 130 can have an actuator 132 and a timer 134. A detection controller 250 of the control unit 110 can obtain sensed information from the detection sensors 116 to detect passage of the launched objects (e.g., balls, darts, etc.) from the launch device 150 to verify proper deployment.

FIG. 10B shows an example operational sequence performed by the system 100 in launching objects (e.g., balls, darts, etc.). To deploy a new object in the flow of fluid to the wellhead 56 (Block 302), the control unit 110 obtains the current position of the cage 180 (Block 304). Then, the control unit 110 determines the new cage position for the desired object to be deployed (Block 306). In most instances, the new cage position will be the next pocket 184 on the cage 180, but this is not strictly necessary.

Before initiating the movement of the cage 180, the control unit 110 unlocks the lock unit 130, if present and engaged, so the cage 180 can be moved (Block 308). The control unit 110 then actuates the motor (120) to move cage 180 (Block 310). The motor's operation may be encoded so the control unit 110 can monitor the movement of the motor 120. As the cage 180 is moved, the control unit 110 obtains the cage position from the motor's encoding and/or from the position sensor(s) 115 and the sensing elements on the cage 180 (Block 312). Eventually, the control unit 110 determines whether the new cage position has been reached (Decision 314).

Once the pocket 184 with the desired object(s) has been reached, the control unit 110 senses whether flow is passing through the launch device 150 (Decision 316). In some forms of operation, the flow to the launch device 150 may be enabled even while the cage 180 is being moved. In other forms of operation, the control unit 110 can actuate the valves (104 and/or 108) to stop flow while the cage 180 is being moved and then to start flow once the desired cage position is reached. If flow is not sensed, then the control unit 110 can actuate the necessary valves (104 and/or 108) to introduce flow through the launch device 150 so that the object in the aligned pocket 184 of the cage 180 can be introduced into the flow (Block 318).

With the flow passing through the aligned pocket 184, the control unit 110 senses the object's passage out of the launch device 150 using the detection sensor(s) 116 (Decision 320). To sense the object(s), the sensor 116 can be a densometer, a proximity sensor, a magnetic sensor, a chemical detector, an RFIID reader, etc. depending on the type of object used. If the object is not sensed as passing the sensor(s) 116 within a specified time, then it is possible that the object has become stuck inside the launch device 150, that the cage 180 did not align properly, that the desired object was not actually loaded in the pocket 184, or that some other problem has occurred.

The control unit 110 then initiates some remedial operations to correct the problem (Block 322). For example, the control unit 110 may actuate the motor 120 to move the cage 180 back toward the previous pocket 184 and then to the desired pocket 184 (Block 310). This can be done in an attempt to realign the desired pocket 184 and redeploy the desired object. Alternatively, in the remedial operations, the control unit 110 may move the cage 180 so that a new object can be loaded in the desired pocket 184 through one of the alternative ports 155 so the system 100 can then deploy that object again.

Once the desired object has been launched and successfully sensed passing from the launch device 150, the control unit 110 can actuate lockout unit 130 until the time when the next object is to be deployed (Block 324). The above operation is meant to be an example of the operation of the launching system 100. A variety of variations can be used, as will be appreciated with the benefit of the present disclosure.

As noted previously, movement of the cage 180 in the housing 160 can be performed in a number of ways. To that end, FIGS. 11A-11C illustrate cross-sectional views of another launch device 150 during stages of operation. Similar components have the same reference numerals as in previous embodiments. In contrast to the cammed movement of the cage 180 seen in previous embodiments, the cage 180 in the present device 150 is moved primarily by linear movement of the shaft 190, which can be coupled to a compatible motor or other actuator. Pockets 184 in the cage 180 have the objects arranged in the desired order linearly along the length of the cage 180. For example, FIG. 11A shows how the objects (e.g., balls) increase in size in the pockets 184 along the length of the cage 180.

During operation, the cage 180 disposed in an initial condition as in FIG. 11A can deploy a first object out the outlet 156 from one of the pockets 184 aligned with the flow through the flow mandrel 170. Then as shown in FIG. 11B, the cage 180 can be moved linearly inside the housing 160 so that adjacent pockets 184 along the cage 180 align between the flow mandrel 170 and the outlet 156 to launch the objects. This can be repeated until the object in the last pocket 184 is launched. At this point, the cage 180 can be rotated inside the housing 160 so that another linear set of adjacent pockets 184 can be selectively aligned with the flow mandrel 170 and outlet 156. Rotation of the cage 180 can be achieved in a number of ways, for example, by using the same motor or actuator to move the cage 180 linearly or by using another motor or actuator. Either way, the end of the shaft 190 can be fixedly coupled to the cage 180 to allow the shaft 190 to both shift and turn the cage 180.

Although not shown, the cage 180 can have a pin, roller, or the like that can ride in a linear channel (not shown) defined on the inside of the housing's chamber 162. This engagement can help keep the movement of the cage 180 linear in the chamber 162. A radial slot defined around the inside of the chamber 162 at its end can then interconnect such a linear channel with another linear channel offset by some angle (e.g., 90 or 180 degrees) from the first linear channel. In this way, the rotation of the cage 180 in the chamber 162 can allows the pin to ride in the radial slot so the pin can then be aligned with the offset channel, down which the cage 180 can be moved back through the chamber 162.

With the cage 180 turned as shown in FIG. 11C, the cage 180 can be moved linearly inside the housing 160 so that each of the adjacent pockets 184 can be selectively aligned with the flow mandrel 170 and outlet 156. Rotation and movement of the cage 180 can be repeated as many times as needed for the linear sets of adjacent pockets 184 along the outside of the cage 180. As will be appreciated, a comparable launch device 150 may not use rotation of the cage 180 so that additional pockets can be used. In this instance, the cage 180 may simply be moved linearly inside the housing 160 and would necessarily be much longer to accommodate more pockets 184 and objects.

As another example, FIGS. 12A-12B illustrate end-sectional and cross-sectional views of yet another launch device 150. Similar components have the same reference numerals as in previous embodiments. In contrast to the rotated movement of the cage 180 seen in previous embodiments, the cage 180 in the present device 150 is moved linearly in the housing 160. Thus, the cage 180 can have a rectilinear or other cross-section (e.g., triangular or other shape) and need not be cylindrical, although that shape may be preferred.

Alternating pockets 184 in the cage 180 have the objects arranged in the desired order linearly and radially along the length of the cage 180. For its part, the housing 160 has alternating outlets 157 a-b disposed around the housing 160 for selectively aligning with one of the successive pockets 184 arranged in the cage 180. (Four outlets 157 a-d are shown, but more or less could be used.) As can be seen, the flow mandrel 170 can have multiple flow ports for alternatingly aligning with the pockets 184 around the cage 180.

During operation, the cage 180 disposed in an initial condition as in FIG. 12A-12B can deploy a first object out one of the outlets 157 c from one of the pockets 184 aligned with the flow through the flow mandrel 170. Then, the cage 180 can be moved linearly inside the housing 160 so that an alternately-arranged pocket 184 along the cage 180 aligns between the flow mandrel 170 and one of the other outlets (e.g., 157 d) to launch the next object. This can be repeated so that each of the alternately-arranged pockets 184 successively aligns with the coordinated outlets 157 a-d.

As an alternative, the pockets 184 can be aligned with one another around the cage 180. When the cage 180 is in one position inside the housing 160, each of the aligned pockets 184 can align with the surrounding outlets 157 a-d. Any one of the pockets 184 can then be used to launch its object by controlling the flow out of the outlets 157 a-d using valves (not shown) selectively actuated by the control unit (110) to permit one or more of the objects to deploy out of one or more of the outlets 157 a-d at a time.

As noted previously with reference to FIG. 2, the launch device 150 may not need to include flow from the pump 52 and tubing 54 of the fluid system 50 to launch the objects. Instead, as shown in FIG. 13, the housing 160 of the launch device 150 can have an outlet 154 communicating with the housing's internal chamber 162. The outlet 154 connects by a conduit 106 to the tubing 54 of the fluid system 50 to the well.

The cage 180 disposed in the internal chamber 162 can define the pockets 184 for holding the objects. As before, the cage 180 can be moved in the internal chamber 162 using the motor 120 and shaft 190. In turn, the movement of the cage 180 selectively positions the cage's pockets 184 in communication with the housing's outlet 154. As the pocket 184 aligns with the outlet 154, the object(s) can launch out of the device 150 by gravity, suction, pressure differential, etc. In this arrangement, the launch device 150 does not require an inlet (152) or a flow mandrel (170) for communicating flow to the pockets 184, as in previous embodiments.

In yet another alternative shown in FIG. 14, the housing 160 of the launch device 150 can have an outlet 156 communicating with the housing's internal chamber 162. The outlet 154 connects by the conduit 106 to the tubing 54 of the fluid system 50 to the well. The housing 160 also has an inlet 152 that connects to an auxiliary fluid source 153 rather than to the tubing 54 of the flow system 50. This auxiliary fluid source 153 can include a pump with its own fluid reservoir, can have a separate type of fluid than used in the fluid system 50, can be a chamber of pressurized fluid, etc. In this device 150, the housing 160 includes a flow mandrel 170 to communicate from the fluid source 153 to the pocket 184 aligned with the outlet 154 so the object(s) can deploy in the fluid system 50 using flow from the auxiliary fluid source 153.

The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. It will be appreciated with the benefit of the present disclosure that features described above in accordance with any embodiment or aspect of the disclosed subject matter can be utilized, either alone or in combination, with any other described feature, in any other embodiment or aspect of the disclosed subject matter.

In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof. 

What is claimed is:
 1. An object launching apparatus for a well, the apparatus comprising: a housing defining an internal chamber and having an inlet and an outlet communicating with the internal chamber; a flow mandrel disposed in the internal chamber and defining a flow passage, the flow passage communicating the inlet of the housing with a flow port of the flow passage, the flow port communicating with the outlet of the housing; and a cage disposed in the internal chamber on the flow mandrel and defining a plurality of pockets for holding the objects, the cage movable on the flow mandrel relative to the flow port and selectively positioning one of the pockets in communication between the flow port of the flow mandrel and the outlet of the housing.
 2. The apparatus of claim 1, wherein the cage is movable at least in a linear direction in the housing relative to the flow port and the outlet.
 3. The apparatus of claim 2, wherein the cage is movable in a radial direction in conjunction with the linear direction in the housing relative to the flow port and the outlet.
 4. The apparatus of claim 1, further comprising a lock movable in the housing relative to the cage and being selectively engageable with the cage.
 5. The apparatus of claim 1, further comprising a shaft disposed in the housing and coupled to the cage, the shaft operable to move the cage at least in a linear direction.
 6. The apparatus of claim 5, wherein a bearing couples the shaft to the cage, the shaft being rotatable in the housing, the bearing moveable along the rotated shaft.
 7. The apparatus of claim 1, wherein a cammed engagement defined between the cage and the internal chamber translates linear movement of the cage to radial movement of the cage in the internal chamber.
 8. The apparatus of claim 7, wherein the cammed engagement comprises: one or more guides disposed on the cage; and a channel defined in an internal surface of the internal chamber defines a channel, the one or more guides riding in the channel.
 9. The apparatus of claim 1, further comprising a motor operably coupled to the cage and operable to move the cage in the internal chamber.
 10. The apparatus of claim 9, wherein a shaft operably couples the motor to the cage, the motor moving the cage in the internal chamber with the shaft, wherein the motor pulls the shaft in the internal chamber, rotates the shaft in the internal chamber, or both pulls and rotates the shaft in the internal chamber.
 11. The apparatus of claim 9, further comprising a controller operably coupled to the motor and controlling movement of the cage in the housing.
 12. The apparatus of claim 1, further comprising an inlet connection coupled to the inlet of the housing and receiving flow for communication with the flow passage of the flow mandrel.
 13. The apparatus of claim 12, wherein the inlet connection comprises a valve operable to control communication of the flow.
 14. The apparatus of claim 12, further comprising an outlet connection coupled to the outlet and supplying the flow to the well.
 15. The apparatus of claim 1, wherein the cage defines an internal passage in which the flow mandrel is disposed.
 16. The apparatus of claim 1, wherein the housing comprises an auxiliary port communicating with the internal chamber, the cage selectively positioning one of the pockets in communication with the auxiliary port.
 17. The apparatus of claim 1, further comprising one or more of: a first sensor detecting position of the cage in the housing; a second sensor disposed toward the inlet and detecting flow of fluid into the inlet; a third sensor disposed toward the outlet and detecting flow of fluid from the outlet; and a fourth sensor disposed toward the outlet and detecting passage of the object launched from the outlet.
 18. An object launching apparatus for a well, the apparatus comprising: a housing defining an internal chamber and having at least one outlet communicating with the internal chamber; and a cage disposed in the internal chamber and defining a plurality of pockets around an axis of the cage for holding the objects, the cage movable in the internal chamber around the axis and selectively positioning at least one of the pockets in communication with the at least one outlet of the housing.
 19. The apparatus of claim 18, wherein the housing comprises an inlet communicating with the internal chamber, and wherein the at least one pocket positioned in communication with the at least one outlet further positions in communication with the inlet.
 20. The apparatus of claim 19, wherein the inlet of the housing is in fluid communication with a fluid source.
 21. The apparatus of claim 19, further comprising a flow mandrel disposed in the internal chamber and defining a flow passage therein, the flow passage communicating the inlet of the housing with at least one flow port of the flow passage, the cage movable on the flow mandrel, the at least one flow port communicating with the at least one outlet of the housing.
 22. The apparatus of claim 21, wherein the cage is movable relative to the at least one flow port of the flow passage to position the at least one pocket in communication between the at least one flow port of the flow mandrel and the at least one outlet of the housing.
 23. The apparatus of claim 22, wherein the cage is movable at least in a linear direction in the housing to align the pockets in communication between the at least one flow port and the at least one outlet.
 24. The apparatus of claim 23, wherein the cage is movable in a radial direction in conjunction with the linear direction in the housing to align the pockets in communication between the at least one flow port of the flow passage.
 25. The apparatus of claim 18, wherein to move the cage in the internal chamber around the axis of the cage, the cage is movable in a linear direction and is concurrently or separately movable in a radial direction in the internal chamber to position the pockets in communication with the at least one outlet.
 26. A method of launching objects into fluid flow directed to a well, the method comprising: communicating an outlet of an internal chamber of a housing with the fluid flow directed to the well; storing the objects in pockets around an axis of a cage disposed in the internal chamber of the housing; positioning selective ones of the pockets in communication with the outlet in the housing by selectively moving the cage around the axis of the cage in the internal chamber of the housing; and deploying the objects in the selectively positioned pockets into the fluid flow directed to the well.
 27. The method of claim 26, wherein selectively moving the cage around the axis of the cage in the internal chamber of the housing comprises moving the cage linearly in the internal chamber.
 28. The method of claim 27, wherein selectively moving the cage around the axis of the cage in the internal chamber of the housing comprises rotating the cage in the internal chamber in conjunction with the linear movement.
 29. The method of claim 28, wherein rotating the cage in the internal chamber in conjunction with the linear movement comprises engaging a guide and channel arrangement between the cage and the internal chamber.
 30. The method of claim 26, wherein positioning selective ones of the pockets of the cage with the outlet in the housing comprises positioning the selective ones of the pockets between an inlet of the housing and the outlet of the housing.
 31. The method of claim 30, wherein positioning the selective ones of the pockets between the inlet and the outlet comprises moving the cage on a flow mandrel communicating with the inlet, the flow mandrel having a flow port communicating with the outlet.
 32. The method of claim 30, wherein deploying the objects in the selectively positioned pockets into the fluid flow directed to the well comprises carrying the objects in the fluid flow communicated from the flow port to the outlet through the selected one of the pockets.
 33. The method of claim 26, further comprising selectively locking the cage in the internal chamber of the housing.
 34. The method of claim 26, further comprising one or more of: detecting position of the cage in the housing; detecting the fluid flow into an inlet of the housing; detecting the fluid flow from the outlet of the housing; and detecting passage of the object deployed from the outlet. 